Interlocking tile carpet



April 26, 1966 s, GAY, JR 3,247,638

INTERLOCKING TILE CARPET Filed May 22, 1963 2 Sheets-Sheet 1 INVENTOR.5751/5 6A Y JR.

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INTERLOCKING TILE CARPET Filed May 22, 1963 2 Sheets-Sheet 2 Fra. 4.

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BY Eon/AED D. 05E/AM Arme/ffy United States Patent C) 3,247,638INTERLUCKING 'liiLE CARPET Steve Gay, Jr., Sepulveda, Calif., assigner,by mesne assignments-to 3 ames W. Fair Filed May 22, 1963, Ser. No.282,350 Claims. (Cl. 52-594) This invention relates to an interlockingtile carpet.

It is well known in the art of carpeting floors that it is diiiicult tolay carpet upon a concrete iioor. The difiiculty, of course, lies withthe fact that securement to concrete is diicult and thus it is diiiicultto engage the edges of the carpet in place. Needlebars are used whichcomprise a bar having upstanding needles which eng-age in the carpet.These are presumably secured to the floor around the periphery of thecarpet area and the carpet is laid thereover. Securing the bars to thefloor is a diicult task when the floor is of concrete construction.Accordingly, such carpets tend to corne loose and do not give goodservice life. Carpet generally has another disadvantage as well. Thisdisadvantage is the wear of areas where trafiic is heaviest. Traliicpatterns soon become notice-able in a new carpet and thus becomeobjectionable, for the carpet does not present the proper uniformappearance as it has when it is in good condition. For best appearance,the whole carpet must be relayed with new material evenV though only 10or 20 percent of the total area shows wear. This, of course, is a wasteof good material and is Iobjectionable for the replacing of unworn areasis a needless waste of labor and material.

Accordingly, itis an object of this invention to provide a carpet thatcan be readily and` conveniently attached to concrete floor.

It is another object of this invention to provide a carpet which can bereplaced in sections so that worn areas may be readily removed andreplaced with new material.

It is another object of 1this invention to provide a carpet attached totile so that sections thereof may be removed and replaced wihoutdisturbing the adjacent carpet tile sections.

It is a further object of this invention to provide a fully interlockingtile carpet so that a minimum of adhesive is necessary to hold thecarpet tile sections in place.

It is another object of this invention to provide fully interlockingcarpet tile where each of the tile elements interlocks with the other sothat individual tiles cannot become loose `or be removed from the tileassembly.

Other objects and advantages of this invention will become apparent froma study of the following specification, `the claims and `the attacheddrawings in. which:

FIGURE l is an elevational section through portions of several tile ofthis invention; =FIGURE 2 is a bottom view of the tile of FIGURE 1,taken along the line 2--2 of FIGURE l;

FIGURE 3 is a section along the interlocking joint between the tile,taken along the line 3-3 of FIGURE 2;

FIGURE 4 is a partial elevational section of one of the interlock-ingtiles of this invention showing ca-rpet att-ached thereto;

FIGURE 5 is a partial side elevational section of an interlocking tileof this invention intended to be used without carpet;

FIGURE 6 is4 a plan view of a iloor having interlocking tile securedthereto, having one tile removed; and

rFIGURE 7 is a plan view of a replacement tile for use in insertion inthe space indicated as being without tile in FIGURE 6.

In summary, this invention is directed to interlocking tile useableeither with or with-out carpet thereon. The

3,247,638 Patented Apr. 26, 1966 interlocking feature is a specialdesign and furnishes interlocking rigidity so that tiles do not shiftwith respect to each other and can be held down with a minimum, or noadhesive. The tile can be used either with or without carpet secured tothe top surface thereof, and the top surface is defined -by a normal,square or rectangular shape. At a plane below the top surface bothfingers and linger receiving recesses of complementary design arefor-med in the tile. These lingers and recesses are of special design sothat they interengage and completely interlock, and once a tile is inplace it cannot move with respect to its adjacent tiles withoutdeformation of parts. This interlocking is accomplished by havinglingers with protuberances extending as interlocking elements, withequivalent recesses to receive these fingers. The basic interlocking isaccomplished by deiining the lower edge by straight Surfaces at an acuteangle to the upper edge of the tile. These straight surfaces define thefingers and recesses referred to above and the lingers provide lockingin three directions. A further, more complete understanding of thisinvention will be had by reference to the drawings.

Referring now .to FIGURE 1, the tile assembly of this invention isindicated generally at 10. The tile is mounted on a floor 12 while inuse, and the tile comprises the basic tile 14, carrying the interlockingmembers, a carpet pad 16 secured theretoand a carpet 18 secured on topof the carpet pad 16. The carpet 13 is conventionally comprised of awoven base 20 and pile 22 stitched thereto. An enlarged section of thisconstruction is seen in FIGURE 3.

As seen in FIGURE 2, tile 14 is the same as several other identicaltiles, one of them being indicated by the numeral 24. FIGURE 2 is abottom view of the adjoining tile and shows the interlocking lingers andassociated recesses in interengagement with each other. The uppersurface of the tile is defined by straight edges 26, 28, 30 and 32.These edges are arranged at right angles to each other, in normalfashion, and deiine the appearance of the tile as seen from the topsurface after it is laid. Conventionally, these edges define a squarebut other con- .ligurationa such as rectangles, are within the purviewof this invention. The mold for the tile of this invention is arrangedin such a manner as to define the straight edges 26 through 32 at thetop surface of the tile 14. rllhe mold also creates interlocking lingersand associated recesses in the lower half of the tile.

As is best seen in FIGURE 2, these fingers and recesses are defined bystraight surfaces which are theedge or rirn of the lower section. Thelower portion is defined by the straight surface 34 which is at an acuteangle with respect to the tile edge 26. The surface 34 adjoins thesurface 36 which is also at an acute angle with respect to the edge line26. These two surfaces define a recess, for -they .are recessed underthe edge defined by the line 26. The surfaces 34 and 36 join each otherin a finger receiving recess portion 33 which is in the form of a halfcircle tangent to the surface 34. The surface 36 may intersect with therecess 38 as a radius, or the surface 4@ may extend tangent to therecess portion 38, parallel to the surface 34 and intersect the surface36. The surface 40 is of such length that the dimension from where thesurface 40 intersects the surface 36 to the end of the circular lingerreceiving recess 38 is approximately equal to the diameter of thehemicircle, or the distance between the surface 34 and the surface 40.This construction thus provides a generally triangular recess having agenerally hemicylindrical additional recess formed at the apex of thetriangle. This entire combination of surfaces provides an undercut foracceptance of the finger on the mating tile is generally indicated at42.

These surfaces 34 and 36 extend beyond the tile edge 36 to form aprotuberant finger 44 which is of such coniiguration as to becomplementary to the recess 42. Thus the protuberant finger 44 includesthe surfaces 34 and 36 which extend outwardly from `the tile edge, as isseen at the lower edge of the tile in FIGURE 2. Here the surfaces 34 and36 extend outwardly from the tile edge 32, each being at an acute anglewith respect thereto. Protuberance 46 is of hernicylindrical formtangent with the surface 34 and joins with the surface 36. The fingerdefined by the surfaces 34 and 36 and the protuberance is ofcomplementary structure to the vrecess 42. The interlocking nature ofsuch tile is shown at the left -tile edge 30 of FIGURE 2 and in ssection thereof in FIG- URE 3. Here, the recess 42 is occupied by afinger 4S on the adjacent tile 24, and finger 44 carrying itsprotuberance at the apex extends into the equivalent recess in themating tile.

The construction is such that the recesses and fingers come together atthe corners of the tile edge for full fitting of the corners.

As seen in FIGURE 4, a tile 5t) is shown having a carpet with a wovenback 52 and pile 54 secured thereto. In this case, the carpet is secureddirectly to the tile 50. This construction is adequate for lessexpensive installations, and is particularly suitable where the tile 50is of such resiliency as .to obviate the need of a separate pad.Similarly, there are some cases where the woven back 52 of the carpethas an additional resiliency and thus eliminates the need for the pad.Such a tile includes the hereinbefore described finger receiving recess38 and fin ger 44. The recessSS includes a suitable space for receivingthe hereinbefore recited protuberance, and the finger 44 carries such aprotuberance for positive interlocking.

FIGURE 5 illustrates a tile 56 which is used in areas where no carpet isnecessary. This tile 56 has the standard, smooth finished tile top andcarries toward its rear surfacethe hereinbefore described fingerreceiving recess 3S and finger 44. The finger 44 carries the hereinbefore recited and described protuberance and the recess is of suitableconfiguration as to receive the finger and protuberance.

FIGURE 6 .and FIGURE 7 illustrate the manner in which an individual tilecan be replaced after damage occurs to an area. Tiles 58, 60, 62, 64,66, 68, 7l) and 72 adjoin the area 74 from which a damaged tile has beenremoved. The tiles 58 through 72 are of any of the ernbodinients ofFIGURES 1, 4 or 5, for this replacement is feasible Whether or notcarpet is secured to the top of the tile. Fingers 4 4 of the adjoiningtile extend into the area 74, and the adjoining tile have recesses of anature hereinbefore described to accept the fingers on the tile which isto be put into the area 74. Tile 76 is the tile which is to be placedinto the open area 74. Itis either specially molded without fingers onopposite edges, or such fingers are removed before installation so thatthe tiles 76 may be slipped into the area '74. Accordingly the underside of the tile '76 is identical to those tile hereinbefore described,except for the removal or absence of the fingers from two opposite edgesthereof. The tile '76 is installed by placing the fingers on one edgethereof into corresponding recesses in an adjacent tile. Thus the ingerson the upper part of `tile 76, as seen in FIGURE 7, engage in therecesses on the under side of tile 66. The tile 76 is then bent untilthe fingers on the lower part of the tile 76, as seen in FIGURE 7, arein such position as to be able to slip into the recesses on the underside of `tile 53.

As can be best seen from FIGURE 2 the protuberances 46 on the fingers44, and the associated recesses 42 on the adjacent tile are such thatthe tile cannot simply be slipped into place, and accordingly cannotsimply be slipped out of place when -the tile is being laid into acorner. One tile may be laid against another by simply slipping it intoplace, but one tile cannot be laid against two others by such slipping.Accordingly the material of the protuberances 46 must be sufficientlyresilient to permit it to deforrn to a sufiicient amount to permit thetile to be laid with edges next to each other. When such deformation isaccomplished, ythen the natural resiliency of the protuberances 46extends then into the accommodating recesses 38 and the tile cannot bedisplaced without sufficient force to again deform the protuberances 46.This provides positively interlocking tile which can be held in placewith minimum adhesive or in some cases, no adhesive at all. It isapparent from this construction that a plurality of fingers and recessesare desirable to interlock the tile along the length of one of itsedges. However, in view of the distortion necessary to place theprotuberances 46 into their appropriate spaces, it may be desirable tohave only one protuberance 46 along each edge of the tile. The number ofsuch protuberances along an edge is determined by several factorsincluding the size of the protuberance, the related angles, thethickness of the protuberance and the resiliency of the material.Each'of these factors affects the amount of force necessary to distortit, resiliently, into the protuberance receiving recess providedtherefore. Accordingly, either these factors must be adjusted, or thenumber of such protuberances 46 along each edge be adjusted so that thetile may be placed in its proper position in a complete layment of tilewithout undue force, yet the tile has sufiicient interlocking strengthfor the circumstances. rIhus, this becomes a balance of factors topermit the tile to be easily laid yetstrongly interlocked into position.

This invention having been described in its preferred embodiment, it canbe seen that it is capable of numerous embodiments within the skill ofthe routine engineer. Accordingly, it is desired that the scope of theinvention be dened by the scope of the appended claims.

I claim:

1. An interlocking floor tile, said fioor tile being defined by upperand lower sides, four edges and interlocking surfaces, said four edgesbeing straight lines and said interlocking surfaces being adjacent ,tosaid edges; said interlocking surfaces comprising surfaces at a firstacute angle with respect to said edges and surfaces at a second acuteangle with .respect to said edges, said surfaces intersecting with eachother a-nd defining triangular interlocking fingers and 'fingerreceiving recesses, said fingers and said iinger receiving recessesbeing located adjacent to each edge of the tile, a protuberance locatedon the apex of at least one of said triangular fingers adjacent each ofsaid edges, and a corresponding protuberance receiv-ing recess adjacenteaoh of said tile edges, whereby a plurality of tile, laid together,interlock with each other with said fingers and said protuberancesengaging in said nger receiving recesses and protuberance receivingrecesses.

2. The interlocking tile of claim 1 wherein said straight edges form asquare, and said square is toward the upper side of said tile.

3. The sti'tucture of claim I wherein a carpet is secured to the upperside of said tile.

4. The struc-ture of claim 3 wherein a carpet pad is located between theupper side of said tile and said carpet.

5. An interlocking tile: said tile bein-g defined by upper and lowersides, four edges and surfaces defining .interlocking lfingers andrecesses;

said upper and lower sides being respectively adapted to be arrangedupward and downward toward the iioor upon which the tile is to bemounted, said upper and lower sides Ibeing substantially plana-r;

said edges being defined 'by straight lines intersecting atsubstantially right angles;

said fingers and finger receiving recesses being deiined by a pluralityof `first surfaces and a plurality of second surfaces, both said firstand second surfaces being arranged at an acute angle with respect `tosaid edges, said edges being toward the upper side and intersecting withsaid upper si-de of said tile and said sur-faces `being adjacent to andintersecting With said lower surface of said tile, said linge-rs andrecesses defined by said surfaces being anranged yfor |mutuallyinterlocking with adjacent tile, a protuberance extending past saidsecond surface mounted on at least one of said nfgers on each of saidside, said recess corresponding to said protuberance carrying ngercontaining a corresponding protuberancereceiving recess, saidprotuberance being of such conguration that it must be resilien-tlydistorted upon laying said oor tile in senies on a floor, whereby saidiioor tile is adapted for posit-ive 'interlocking upon installation upona tloor. 6. The floor tile of claim 5 wherein a carpet lis secured to.the upper side of said tile.

7. The carpet tile of claim 6 wherein a carpet pad is secured betweensaid tile and said carpet.

8. The structure of claim 5 whe-rein lthe upper side of said tile isarranged to be the visible, wear area of said tile.

9. The structure of claim 5 wherein said surfaces and 6 said edgesintersect -at the intersection of said edges of said tile.

10. The floor 'tile of claim 5 wherein said -protuberance 4isresiliently distorted when said Hoor tile is laid in series with similarfloor tiles upon a oor and said pro-tuberance substantially :returns toits previous configuration after such distortion and after it ispositioned within a corresponding pnotuberance receiving recess so thatsaid floor tile is adapted -for positive interlocking yin both an upwardand edigeWa-rd direction.

References Cited by the Examiner UNITED STATES PATENTS 928,320 7/1909Moore 50449 1,473,767 1l/l923 Healy 50-450 2,246,101 7/1941 McEnany 20-7X 2,708,329 5/l955 McKee 50--448 3,082,488 3/ 1963 Nusbaum 20--8HARRISON R. MOSELEY, Primary Examiner. REINALDO P. MACHADO, Examiner'.

1. AN INTERLOCKING FLOOR TILE, SAID FLOOR TILE BEING DEFINED BY UPPERAND LOWER SIDES, FOUR EDGES AND INTERLOCKING SURFACES, SAID FOUR EDGESBEING STRAIGHT LINES AND SAID INTERLOCKING SURFACES BEING ADJACENT TOSAID EDGES; SAID INTERLOCKING SURFACES COMPRISING SURFACES AT A FIRSTACUTE ANGLE WITH RESPECT TO SAID EDGES AND SURFACES AT A SECOND ACUTEANGLE WITH RESPECT TO SAID EDGES, SAID SURFACES INTERSECTING WITH EACHOTHER AND DEFINING TRIANGULAR INTERLOCKING FINGERS AND FINGER RECEIVINGRECESSES, SAID FINGERS AND SAID FINGER RECEIVING RECESSES BEING LOCATEDADJACENT TO EACH EDGE OF THE TILE, A PROTUBERANCE LOCATED ON THE APEX OFAT LEAST ONE OF SAID TRIANGULAR FINGERS ADJACENT EACH OF SAID EDGES, ANDA CORRESPONDING PROTUBERANCE RECEIVING RECESS ADJACENT EACH OF SAID TILEEDGES, WHEREBY A PLURALITY OF TILE, LAID TOGETHER, INTERLOCK WITH EACHOTHER WITH SAID FINGERS AND SAID PROTUBERANCES ENGAGING IN SAID FINGERRECEIVING RECESSES AND PROTUBERANCE RECEIVING RECESSES.